UNIT 8

CONTRIBUTE TO QUALITY
SYSTEM

Learning Objectives....................................................191
Introduction.................................................................192
Inspect Work Done....................................................192
Apply Quality Standards to Work..........................206
Protect Company Property and Customer
Interests........................................................................213
Unit Summary............................................................222
Points of Discussion...................................................222
Multiple Choice Questions.......................................222
References....................................................................224

LEARNING
OBJECTIVES
After completing this unit, you are expected to:
• Inspect work done
• Apply quality standards to work
• Protect company property and customer
interests
Shielded Metal Arc Welding: Beginner

INTRODUCTION
Manual Metal Arc (MMA) welding is the most flexible and one of the most widely used arc
welding processes. It involves striking an arc between a covered metal electrode and a work
piece. The heat of the arc melts the parent metal and the electrode which mix together to
form, on cooling, a continuous solid mass. The most common quality problems associated
with SMAW include weld spatter, porosity, poor fusion, shallow penetration, and cracking.
Weld spatter, while not affecting the integrity of the weld, damages its appearance and
increases cleaning costs. Secondary finishing services are often required due to the aesthetic
appearance caused by the occurrence of molten splatter. It can be caused by excessively high
current, a long arc, or arc blow, a condition associated with direct current characterized by
the electric arc being deflected away from the weld pool by magnetic forces. Arc blow can
also cause porosity in the weld, as can joint contamination, high welding speed, and a long
welding arc, especially when low-hydrogen electrodes are used.
Porosity, often not visible without the use of advanced nondestructive testing methods,
is a serious concern because it can potentially weaken the weld. Another defect affecting
the strength of the weld is poor fusion, though it is often easily visible. It is caused by
low current, contaminated joint surfaces, or the use of an improper electrode. Shallow
penetration, another detriment to weld strength, can be addressed by decreasing welding
speed, increasing the current or using a smaller electrode. Any of these weld-strength-related
defects can make the weld prone to cracking, but other factors are involved as well. High
carbon, alloy or sulfur content in the base material can lead to cracking, especially if low-
hydrogen electrodes and preheating are not employed.

INSPECT WORK DONE

Many characteristics of a weld can be evaluated during welding inspection - some relating to
weld size, and others relating to the presence of weld discontinuities. The size of a weld can
be extremely important, as it often relates directly to the weld’s strength and performance.
For instance, undersized welds may not withstand stresses applied during service.
Depending on their size and/or location, weld discontinuities (imperfections within or
adjacent to the weld) can prevent the weld from meeting its intended performance. Weld
discontinuities are often referred to as welding defects, and they can sometimes cause

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premature weld failure due to a reduction of strength or added

stress concentrations within the welded component.
Weld inspections are conducted for several reasons, the most
common of which is to determine whether the weld is of suitable
quality for its intended application. To evaluate the quality of a
weld, you must first have criteria to which you can compare the
weld’s characteristics. Codes and standards developed specifically
for a variety of welding fabrication applications are used during
welding inspections to dictate what levels of weld discontinuities
are acceptable. It is important to choose a welding standard that KEY WORD
is intended for use within your industry or application. Codes are generally
Quality acceptance criteria can originate from several sources. the top-tier documents,
providing a set of rules
The welding fabrication drawing or blueprint will typically
that specify the minimum
provide sizes and other dimensional information, such as acceptable level of
length and location of welds. These dimensional requirements safety for manufactured,
are typically established through design calculations or are fabricated or constructed
taken from proven designs known to meet the performance objects.
requirements of the welded connection.

Inspection and Testing for Welding

Procedure Qualification
Welding Procedures are the guidelines used to perform a weld.
They are designed to provide a record of the welding variables
used and the inspection results obtained during the procedure
qualification test. They can also provide the instructions for the
welder to use in production in order to produce acceptable welds.
Usually welding procedures are developed in accordance with
a welding code or standard, and with few exceptions*, require
that physical weld samples be produced, inspected, and tested to
establish qualification. Welding procedures are usually divided

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into two categories, the Procedure Qualification Record (PQR) and the Welding Procedure
Specification (WPS). Procedure Qualification Records are the documented values used during
the actual welding test and all the inspection and test results obtained from the actual test
samples. Welding Procedure Specifications are usually documented work instructions that can
be used by the welder to conduct welding operations, and are based on, but not necessarily
the same as, the parameters used for the Procedure Qualification Record. We will consider
the Procedure Qualification Record and the inspection and testing performed during its
qualification. Qualification testing of a welding procedure normally requires documentation
to show all the variables used during the welding test and the documented inspection and
test results. The variables required to be documented are typically such items as: welding
process used, size, type and classification of filler alloy, type and thickness of base material
welded, type and polarity of welding current, amps and volts recorded, travel speed during
welding, welding position, type and dimensions of joint design, preheating temperature,
interposes temperature, post weld heat treatment details, and others. In addition to the
recording of all the welding variables used during the test, in order to qualify a welding
procedure, details of the inspection and test results must also be recorded. These records
must show that the inspection and testing has proven that the weld samples have met or
exceeded the specified standard requirement. The typical types of inspection and testing for
each sample for Welding Procedure Qualification are:
Procedure Qualification Record (PQR) is a record of a test weld performed and tested (more
rigorously) to ensure that the procedure will produce a good weld.

Inspection and Testing for Fillet Welds (Tee Joints): This involves visual inspection
of the completed weld, followed by two macro etches, and one fillet weld break test. The
welded sample is first inspected for any visual discontinuities and then sectioned, and two
small samples removed at predetermined locations. These small samples are polished across
their cross-section and then etched using some type of mild acid mixture, dependent on
the base material used. The remaining welded sample is used as the fillet weld break test
and is broken against the weld to reveal the internal structure of the weld for inspection.
Inspection and Testing for Groove welds (Butt Joints): This involves visual inspection,
followed by two transverse tensile tests, two root bend test and two face bend tests. (These tests
are typical but may differ dependent on material thickness, type and standard requirements.
Different and/or additional testing, such as side bends, all weld tensile tests, impact testing
or other testing may be required.) The completed weld coupon, after visual inspection, is
divided into predetermined small sections. Each section is prepared, usually by machining,

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to specific dimensions as prescribed by the standard. Each small sample is then tested
mechanically to determine its characteristics. These samples are then inspected to determine
their acceptability, against specified acceptance criteria, as laid down by the applicable code
or standard. Typically the standard will provide the maximum size and location of various
weld discontinuities and/or, as relevant, values such as minimum tensile strengths or minimum
desired impact properties. Samples that are found not to have discontinuities that exceed these
specified limits, and that meet or exceed the minimum values as specified in the standard,
will be acceptable, and the welding procedure will be qualified. The welding procedure is
an important part of the overall welding quality system, as it provides documented evidence
that inspection and testing has been performed to ensure that welding can be conducted
to meet a recognized standard. One exception to welding procedure qualification is the
D1.1 Structural Welding Code for Steel, which will, under some circumstances, allow the
use of pre-qualified welding procedures, however these procedures are still required to be
documented and meet all of the relevant code requirements. 

Properties of Shielding Gases

Carbon dioxide and argon respond in different ways under the heat of the arc. Three basic
criteria are useful in understanding the properties of each shielding gas.
• Ionization potential is a measure of the energy required to ionize the gas (i.e. 
Transform to a plasma state in which it is positively charged), enabling the gas
to conduct current.  The lower the number, the easier it is to initiate the arc and
maintain arc stability. The ionization potential for CO2 is 14.4 eV, versus 15.7 eV for
argon. Thus, it is easier to initiate an arc in pure CO2 than in pure argon.
• Thermal conductivity of a gas is its ability to transfer thermal energy. This affects
the mode of transfer (spray versus globular, for example), shape of the arc, weld
penetration and temperature distribution within the arc. CO2 has a higher thermal
conductivity level than argon and an Ar / CO2 blend.
• Reactivity  of a gas is a classification as to whether or not it will chemically react
with the molten weld puddle. Gases can be divided into two groups, inert and active.
Inert gases, or noble gases, are those that are unreactive with other elements in the
weld puddle. Argon is an inert gas. Active gases, or reactive gases, are those that
combine or react with other elements in the weld puddle to form compounds. At

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room temperature, CO2 is inert.  However, in the arc plasma, CO2 will disassociate,
forming CO, O2 and some monotonic O. Therefore, CO2 becomes an active gas in
the welding arc, allowing the oxygen to react with metals (i.e. oxidize) in the arc.
An Ar / CO2 blend is also an active gas, but less reactive than 100% CO2.
With all other welding variables being the same, different shielding gases produce different
welding fume generation rates. Typically, there is reduction in rates with an Ar/CO2 blend,
as compared to CO2, due to the oxidizing potential of CO2. Specific fume generation levels
vary and are dependent on the particular application and welding procedures used.
Inspection Areas FCAW welders need to ensure that all aspects of the operation are
performed correctly.

At a minimum, welders should check the following areas:

• Base material is as specified.
• Joint design is as specified and within required tolerances.
• Filler metal type and size are correct.
• Required welding equipment is available and operating satisfactorily.
• Tooling has been adequately tested to determine that it will properly support the
operation.
• Parts have been properly cleaned.
• Welder training or certification is sufficient for the weld operation.
• Proper welding procedure is used and the welding equipment is set up properly
for the operation.
• Inspections and tests required during the welding operation are performed as specified.
• Completed weld has been inspected to ensure that it will meet the visual requirements.
Additional nondestructive examination is usually performed by other personnel.

Appropriate Inspections Conducted to Flux Welding

Company
Inspecting construction sites to ensure that appropriate controls are in place is another key
element of an effective health and safety program. Informal inspections should be done by
all supervisors whenever they are out on site.

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The welding inspector is a quality representative of any

if the parties involved in a weld related projects, either the
manufacturer, the customer, the regulation authorities or other
third party assigned by the parties. The inspector must have
the right skills and knowledge and an appropriate certification.
He has to determine the compliance of the weld quality to
the drawing or the standard requirement. The inspector is not
allowed to make waiver or to confirm changes of the weld
process parameters (WPS).

Quality system and procedures

There are some quality system and procedures such as: KEY WORD
• work instructions Work instruction
• safe work procedures describes how to
perform a task within
• product specifications a process, which is a
• equipment maintenance schedules more detailed portion
of the procedure such
• technical procedures adopted or specifically prepared as “Completing a PO”
standards or “Ordering supplies.”
• company/industry rules

Job Specifications in Flux Welding

Welders use various kinds of equipment and processes to
create the heat and pressure needed to melt the edges of metal
pieces in a controlled fashion so that the pieces may be joined
permanently. The processes can be grouped into three categories.
The arc welding process derives heat from an electric arc between
two electrodes or between an electrode and the work piece.
The gas welding process produces heat by burning a mixture
of oxygen and some other combustible gas, such as acetylene
or hydrogen. The resistance welding process obtains heat from
pressure and resistance by the work piece to an electric current.

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Two of these processes, the arc and gas methods, can also be
used to cut, gouge, or finish metal. Depending on which of these
processes and equipment they use, welders may be designated arc
welders, gas welders, or acetylene welders; combination welders
(meaning they use a combination of gas and arc welding); or
welding machine operators (meaning they operate machines
that use an arc welding process, electron-beam welding process,
laser-beam welding process, or friction welding process). Other
workers in the welding field include resistance machine welders;
KEY WORD oxygen cutters, who use gas torches to cut or trim metals; and
arc cutters, who use an electric arc to cut or trim metals.
Alloy is a combination of
metals and of a metal or Skilled welders usually begin by planning and laying out
another element. Alloys are their work based on drawings, blueprints, or other specifications.
defined by a metallic bonding Using their working knowledge of the properties of the metal,
character.
they determine the proper sequence of operations needed for
the job. They may work with steel, stainless steel, cast iron,
bronze, aluminum, nickel, and other metals and alloys. Metal
pieces to be welded may be in a variety of positions, such as
flat, vertical, horizontal, or overhead.

In the manual arc welding process (the most commonly used

method), welders grasp a holder containing a suitable electrode
and adjust the electric current supplied to the electrode. Then they
strike an arc (an electric discharge across a gap) by touching the
electrode to the metal. Next, they guide the electrode along the
metal seem to be welded, allowing sufficient time for the heat of
the arc to melt the metal. The molten metal from the electrode
is deposited in the joint and, together with the molten metal
edges of the base metal, solidifies to form a solid connection.
Welders determine the correct kind of electrode to use based
on the job specifications and their knowledge of the materials.
In gas welding, welders melt the metal edges with an intensely
hot flame from the combustion of fuel gases in welding torches.
First, they obtain the proper types of torch tips and welding
rods, which are rods of a filler metal that goes into the weld
seam. They adjust the regulators on the tanks of fuel gases, such
as oxygen and acetylene, and they light the torch. To obtain

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the proper size and quality of flame, welders adjust the gas valves on the torch and hold
the flame against the metal until it is hot enough. Then they apply the welding rod to the
molten metal to supply the extra filler needed to complete the weld.
Maintenance welders, another category of welding workers, may use any of the various
welding techniques. They travel to construction sites, utility installations, and other locations
to make on-site repairs to metalwork.
• Knowledge of materials, tools, and processes used in gas, arc, and Heli-arc welding.
• Knowledge of the welding qualities and properties of a variety of metals.
• Knowledge of occupational hazards and safety precautions applicable to the welding
trade.
• Skill in the welding of ferrous and nonferrous metals.
• Ability to read and independently work from plans, sketches, diagrams, and blueprints.
• Ability to train, instruct, and direct others in welding work.
• Ability to communicate effectively.

Work Order and Quality Standards

Welding is a way to make high strength joints between two or more parts. Multi-Positional
Welders use high electrical energy to form an arc. Manual dexterity is essential in controlling
the arc, which is used to melt metals, allowing them to fuse together to form a structurally
sound weld. Welding is used extensively and in almost every sector of industry. There is a
high demand for Multi-Positional Welders in areas such as: power generation, oil and gas,
marine, transport, nuclear, processing, and aerospace, pharmaceuticals, construction and
many more. Multi-Positional Welders make items such as: pressure containment equipment,
pressure pipework, offshore jackets, submarines, military vehicles and equipment and aero
engine components.

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Multi-Positional Welders are able to work with a range of welding processes, with different
metals, to the levels of quality and inspection required in safety critical applications. The
finished welds are often subjected to rigorous inspection and testing. Multi-Positional Welders
are therefore required to consistently perform to high standards in order to ensure that the
finished products function correctly, contributing to the safety of all and the global quality
of life. Skilled, qualified, professionally certified Multi-Positional Welders can work anywhere
in the world and provide services in the harshest of environments. For these accomplished
professionals, the monetary rewards can be significant. There is a highly complex range of
welding skills: the different arc welding processes require different levels of manual dexterity,
knowledge and skill to avoid making defective welds. There are a wide range of metallic
materials that can be welded all with different properties and behaviors.

Faults Identified According to Company Procedures

Fault detection, isolation, and recovery is a subfield of control engineering which concerns
itself with monitoring a system, identifying when a fault has occurred, and pinpointing
the type of fault and its location. Two approaches can be distinguished: A direct pattern
recognition of sensor readings that indicate a fault and an analysis of the discrepancy between
the sensor readings and expected values, derived from some model. In the latter case, it is
typical that a fault is said to be detected if the discrepancy or residual goes above a certain
threshold. It is then the task of fault isolation to categorize the type of fault and its location
in the machinery. Fault detection and isolation techniques can be broadly classified into two
categories.

Quality system and procedures

Quality system and procedures may be contained in:

Work instructions
It is the duty of a proprietor or an employer to provide a safe and healthy working environment
for the employees. Failure to provide a safe working environment for the welding workers
is often the fundamental cause of accidents or health problems to them. It is essential to
always maintain a high standard of housekeeping at the workplace. A tidy workplace can
substantially reduce the risks of accidents. The points to note in providing a safe working
environment for manual electric arc welding operations include:

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Safe work procedures

(a) welding equipment, cables, and other equipment should be suitably placed to avoid
imposing hazards, e.g. electric shock, tripping, etc., on the welding workers and
other workers;
(b) proper warning signs and notices should be displayed at the welding equipment and
the workplace as appropriate to alert the welding workers the DOs and DON’Ts,
e.g. use of personal protective equipment, fire hazard, etc;
(c) the welding worker and other workers in the vicinity of welding workplace should
be protected from the heat, radiation, sparks and welding spatters by suitable screens
and shields;
(d) fire fighting equipment, e.g. portable fire extinguishers, sand buckets, etc., should
be provided in the welding workplace and its vicinity;
(e) any combustible/ flammable materials, e.g. grease/ oil, fuel, paint, wooden materials,
etc. being used or stored in the welding workplace or its vicinity should either
be removed or be suitably and adequately covered by non-combustible or flame
retardant materials; and
(f) any water ponding, flooding or dripping/ splashing of water in the welding workplace
and its vicinity should be avoided.

Product specifications
The project activities include three components: Designing aggregated purchasing schemes
for energy efficient electrical equipment. Designing electricity service agreements. Business
development support (to business using energy)
• Electric motors for operating different machines such as milling machines, water
pump etc.
• Electric welding machines which are considered as means to support the establishment
of small rural based metal fabrication industries which are vital to rural production
and security
• Electric lighting for rural enterprises, households, hospitals, schools etc.

Welding Machine Specification

The following Table shows the General Technical Requirements for Energy Efficiency Welding
machines

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Equipment Maintenance Schedules

Whether you’re talking about an arc, gas, MIG or TIG welder, a little preventive maintenance
will go along way toward getting a long and productive life out of your welding equipment.
With so many shops today having one or more welders, and most industrial plants
employing welding equipment for maintenance and production, the need to maintain that
equipment is greater than ever.
Welders can often costs thousands of dollars or more, and replacement parts can be
scarce and quite expensive. So the maintenance of welding equipment is essential to keeping
costs down and production going at optimum levels.

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The maintenance of welding equipment will differ depending on the type of welder in
question. Arc welder maintenance, for example, will depend on whether it’s an AC or DC
unit. And an oxyfuel welder will require an entirely different maintenance program to keep
it in good working order.

A good place to start is by thoroughly inspecting your equipment at least every 3

months. Clean all dust and dirt from the welding and other accessories, clean and lubricate
the bearings with the proper grease, and check brushes to make sure they’re making contact
with the commutator. Also clean switches, connectors and relays on a regular basis.

A.C. Arc Equipment  Maintenance

Here the type and level of maintenance of welding equipment depends on whether the motor
generator is a transformer or doc type. With a transformer unit, the transformer will need to
be cleaned at least twice per year by blowing it out with low pressure air hose. Then you’ll
want to tighten any loose electrical connections, and oil the bearings on the ventilating fans
if they’re not sealed bearings.

POINTS TO REMEMBER
• It’s a good idea to set up a regular welder maintenance schedule and stick to all
year round. This will ensure that your machine is kept in good operating condition
at all times, and the equipment should last longer and need fewer costly repairs.

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Do an inspection of the condensers, and check for any

dielectric oil that may be leaking from the unit. Also clean any
pilot relay contents on the welder, using a cloth that’s been soaked
with naptha or another solvent. Never use abrasive cleaners on
the contacts, and never force the contact arms apart.

D.C. Arc Equipment Maintenance

With DC motor generator arc welders, a more extensive
maintenance program is needed due to the fact that these units
have more moving parts that are subject to additional wear.
At least once per week you’ll want to inspect the brushes on
the unit for wear. Replace any brushes that are short, cracked or
brittle or worn. Always make sure the replacement brushes are
of the same grade as recommended by the manufacturer. Also
check the brush springs for to make sure they’re not cracked
or worn out.

DID YOU KNOW?

During the 1920s,
major advances were
made in welding
technology, including
the 1920 introduction Another item to check is the color of the commentator – a
of automatic welding reddish or bluish tint indicates overheating. A deep brown
in which electrode color indicates a commentator in good operating condition. If
wire was continuously the commentator is too badly worn, it may be necessary to turn
fed. Shielding gas the component on a lathe to bring it back into good operating
became a subject condition.
receiving much Next you’ll want to blow out the machine with a low-pressure
attention as scientists air hose. Blow out the field coils, motor coils and the armature.
attempted to protect Try to remove all dust, debris and metal filings from the machine.
welds from the effects Lubricate any bearings or any other moving parts that require
of oxygen and nitrogen grease or oil. Replace any frayed or defective wiring, connections
in the atmosphere. or insulation. Also check all the controls on the welder, making
sure they’re well-adjusted and functioning correctly.

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Oxyfuel Equipment Maintenance

Maintenance of gas and oxyfuel welding equipment is more extensive than other types
due to the fact that with these welders, any excessive wear or damage to pressure parts can
lead to very serious trouble. Every day the gas and oxygen manifolds and piping will need
to be inspected for cracks or leaks. Because oxygen is supplied at much higher pressure
(from 60 to 110 psi) than acetylene (only about 15 psi) you’ll need to check the pressure
regulators at each of the blowpipe stations very thoroughly. You’ll also want to check the
hose pressure on the hoses leading to the blowpipe every day as well, preferably with a
hypodermic needle-type pressure gauge.
One tip is to use a soap and water solution to detect leaks in acetylene and oxygen hoses
and pipes, similar to how you would check for a leak in a bicycle inner tube. Apply the
soap and water solution evenly over the hoses, and watch for any bubbles that may appear.
Another critical component in an oxyfuel welder is the flash arrestor. The flash arrestor is
used to prevent oxygen from passing into the acetylene lines, which can be a very dangerous
situation. Needless to say, the arrestor needs to be kept in top-notch condition at all times.
Also check the acetylene and oxygen shutoff valves for any leakage. Always replace any
defective regulators or gauges immediately, with new or quality reconditioned ones.
One other important area to check is the blowpipe tips. Carbon or slag can build up in
the tips, restricting the flow of oxygen or acetylene. This buildup can usually be knocked
off with a small hammer, but be careful not to dent or damage the orifice. Also check to
make sure the tips are square and smooth before returning them.

Technical procedures adopted or specifically prepared standards

OSHA has standards that cover many aspects of welding work, including welding safety,
welding in confined spaces, handling of compressed gases, fire and electrical safety, ventilation,
protective equipment, and worker training. Insist on safe working conditions before welding.
Specific requirements for assuring the safety of welding, cutting, and brazing operations are
covered under OSHA Standard 29 CFR 1910.252. Below are some selected requirements of
the standard:
• Compressed gas cylinders must be kept away from radiators and other heat sources
and stored upright in a well-ventilated, dry location at least 20 feet from highly
combustible materials such as oil. Cylinders should be kept away from elevators,
stairs, or other spaces where they can be knocked over or damaged.
• Piping systems must be tested and proved gastight at 1 1/2 times the maximum
operating pressure, and shall be thoroughly purged with air, before being placed in

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service. Service piping systems must be protected by pressure relief devices.

• Hoses showing leaks, burns, worn places, or other defects must be repaired or
replaced.
• Cutters and welders must be suitably trained in the safe operation of their equipment
and the safe use of the process.
• The welder should be enclosed in an individual booth, or by non-combustible screens,
that are painted with a finish of low reflectivity such as zinc oxide or lamp black (to
absorb ultraviolet radiation).Other people next to the welding area must be protected
by noncombustible or flame proof screens or be required to wear appropriate goggles.
• The booths or screens should permit circulation of air at the floor level.
• All movable fire hazards in the vicinity of welding operations must be taken to a
safe place. If all the fire hazards cannot be moved, guards must be used to contain
the heat, sparks, and slag.
• Suitable fire extinguishing equipment must be maintained ready for instant use.
• Firewatchers are required whenever welding or cutting is performed in a location
where other than a minor fire might develop. A fire watch must be maintained for
at least 1/2 hour after completion of welding or cutting operations to detect and
extinguish possible smoldering fires.
• No welding, cutting, or other hot work shall be performed on used drums, barrels,
tanks, or other containers until they have been thoroughly cleaned (a purge with
an inert gas is also recommended).
• Eye protection must be used during all arc welding or arc cutting operations, gas
welding, oxygen cutting, resistance welding, or brazing operations (the proper shade
number should be selected).
• When a welder must enter a confined space through a manhole or other small
opening, an attendant with a pre-planned rescue procedure must be stationed outside
to observe the welder at all times and to put the rescue operation into effect, if
necessary.
• Special ventilation and/or respirators are required in confined spaces, for cleaning
compounds, when fluorine compounds, zinc, lead, beryllium, cadmium, and mercury
are encountered, and when cutting stainless steel.
• Warning labels are required for all filler metals and fluxes containing fluorine
compounds (fluorides).

APPLY QUALITY STANDARDS TO WORK

There are a number of reasons to inspect a weld, the most fundamental of which is to
determine whether its quality is good enough for its intended application. To evaluate the
quality of a weld, it is necessary to have a form of measurement to compare its characteristics

PROGRESS CHECK
1. Discuss about oxyfuel equipment maintenance.
2. Focus on flux welding.

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and a qualified individual to perform the evaluation. It is not practical to evaluate quality
without some form of specified acceptance criteria. It’s also not practical for a person who
is not well-versed in the necessary procedures to perform this task.
Evaluation of weld characteristics includes the size of the weld and the presence of
discontinuities. The size of a weld can be extremely important, as it often correlates directly
to strength and associated performance. Undersized welds may not withstand stresses applied
during service, and oversized welds can produce stress concentrations or contribute to the
potential for distortion of a welded component.
Uncovering weld discontinuities also is important because imperfections within or adjacent the
weld, depending on their size or location, may prevent the weld from meeting its intended
function. When discontinuities are an unacceptable size or in an unacceptable location, they
are called welding defects, and they can cause premature weld failure by reducing strength
or producing stress concentrations within the welded component.

Determining Weld Quality

Weld quality acceptance criteria can originate from a number of sources. The welding fabrication
drawing or blueprint provides weld sizes and other welding dimensional requirements such
as length and location. These dimensional requirements are established through design
calculations or are taken from proven designs that meet the performance requirements of
the welded connection.

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The number of acceptable and unacceptable weld discontinuities for welding inspection
usually is obtained from welding codes and standards. Welding codes and standards have
been developed for many types of welding fabrication applications. It is important to choose
a welding standard intended for use within the particular industry or application in which
you are involved.

Weld Inspector Responsibilities

Welding inspection requires a knowledge of weld drawings, symbols, joint design, procedures,
code and standard requirements, and inspection and testing techniques. For this reason,
many welding codes and standards require that the welding inspector be formally qualified,
or have the necessary knowledge and experience to conduct the inspection.
Weld inspection is only as good as the person running the tests. Here are a few things
that a welding inspector should know and tasks he should be able to perform:
• Welder Performance and Welding Procedure Qualification. Specific procedures must
be followed to qualify welders and welding procedures. The qualification process
is an integral part of the overall welding quality system, and the welding inspector
often is required to coordinate and verify these types of qualification tests.
These qualifications typically involve producing welded samples representative of the
welds that will be used in production welding. These welded samples usually are required
to be tested after completion. Radiographic, micro etching, guided bends, transverse tension,
and nick-break fracture are some of the tests that are used. The test results must meet or
exceed the minimum requirements as stipulated in the welding code or standard before the
procedure can be qualified.
• Visual Inspection. This is often the easiest, least expensive, and most effective method
of welding inspection for many applications if performed correctly. The welding
inspector must be capable of identifying all of the different welding discontinuities
during visual inspection. He also must be able to evaluate, in terms of the relevant
welding code or standard, the significance of identified discontinuities to determine
whether to accept or reject them during testing and production.
A welding inspector with good eyesight can be trained relatively quickly by a competent
instructor and can prove to be a major asset to the welding quality system (good vision is
obviously essential for visual inspection).
• Surface Crack Detection. A welding inspector sometimes is required to conduct weld
testing by surface crack detection methods. He also may have to evaluate the test
results of these testing methods. The inspector should understand testing methods,
such as liquid penetrant and magnetic particle inspection. Additionally, he must
know how the tests are used and what they will find.
• Radiographic and Ultrasonic Weld Inspection. These two inspection methods are
in a group known as nondestructive testing (NDT). These inspection methods are
used to examine the internal structure of the weld to establish the weld’s integrity,
without destroying the welded component. The welding inspector may be required
to understand this type of testing and be competent in the interpretation of the
results. Radiographic and ultrasonic weld inspection are the two most common
methods of NDT used to detect discontinuities within the internal structure of welds.
The obvious advantage of both methods is their ability to help establish the weld’s
internal integrity without destroying the welded component.
Radiographic testing makes use of X-rays produced by an X-ray tube or gamma rays
produced by a radioactive isotope. The basic principle of radiographic inspection is the same

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as that for medical radiography. Penetrating radiation is passed through a solid object, in this
case a weld, onto a photographic film, resulting in an image of the object’s internal structure.
The amount of energy absorbed by the object depends on its thickness and density. Energy
not absorbed by the object will cause exposure of the radiographic film. These areas will be
dark when the film is developed. Areas of the film exposed to less energy remain lighter.
Therefore, areas of the weld where the thickness has been changed by discontinuities,
such as porosity or cracks, will appear as dark outlines on the film. Inclusions of low density,
such as slag, will appear as dark areas on the film, while inclusions of high density, such as
tungsten, will appear as light areas. All discontinuities are detected by viewing shape and
variation in density of the processed film.
Ultrasonic testing makes use of mechanical vibrations similar to sound waves but of higher
frequency. A beam of ultrasonic energy is directed into the weld to be tested. This beam
travels through the weld with insignificant loss, except when it is intercepted and reflected
by a discontinuity. The ultrasonic contact pulse reflection technique is used. This system
uses a transducer, which changes electrical energy into mechanical energy. The transducer
is excited by a high-frequency voltage, which causes a crystal to vibrate mechanically. The
crystal probe becomes the source of ultrasonic mechanical vibration.
These vibrations are transmitted into the test piece through a coupling fluid, usually
a film of oil, called a couplant. When the pulse of ultrasonic waves strikes a discontinuity
in the test piece, it is reflected back to its point of origin. Thus, the energy returns to the
transducer. The transducer now serves as a receiver for the reflected energy. The initial signal
or main bang, the returned echoes from the discontinuities, and the echo of the rear surface
of the test piece are all displayed by a trace on the screen of a cathode-ray oscilloscope.

• Destructive Weld Testing. Destructive methods to establish weld integrity or

performance include sectioning, bending, or breaking the welded component and
evaluating various mechanical or physical characteristics. Some of these tests are
the guided bend test, macroetch test, reduced section tensile test, fracture test, and
Charpy V-notch impact test. These tests are used during welding procedure or
welder performance qualification testing. The welding inspector often is required
to conduct, supervise, or evaluate these testing methods.

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• Interpretation of Welding Details and Weld Symbols. The

welding inspector should be competent in the ability to
read engineering and manufacturing drawings, and be
able to interpret all details and symbols that provide
information about the welding requirements.
By looking at only some of the welding inspector’s functions,
it is easy to see that the welding inspector can have many
responsibilities. These duties generally change from one
engineering or manufacturing environment to another. However,
the welding inspector’s primary job is to help coordinate the
welding quality control operations within the organization.
One of the main ingredients of a successful welding quality control
system is the establishment, introduction, and control of a sound
welding inspection program. A program can be established only
after completing an evaluation of the weld quality requirements
or acceptance criteria, acquiring knowledge of the inspection and
testing methods, and using properly qualified and experienced
welding inspectors.

Production/Fabrication Process of
SMAW
The fabrication of marine and offshore structures requires the
welding together of individual components such as steel plates
or pipe joints. The permanent process of welding has allowed the
construction of modern ships, offshore structures, and pipelines
to be made possible. This article looks at the different welding
processes that are commonly used in the industry today. There
are many types of welding processes, but the main ones used for
marine construction are shielded metal arc welding (SMAW), gas
metal arc welding (GMAW), submerged arc welding (SAW), flux‐
KEY WORD cored arc welding (FCAW), and gas tungsten arc welding (GTAW).
Welding Procedure
The advantages and disadvantages of each of these are discussed.
Specification (WPS) Additionally, important welding/welder qualification processes
is the formal written such as welding procedure specification (WPS), procedure
document describing qualification record (PQR), welder performance qualification
welding procedures, record (WPQR), pipe welding positions, terminology for the
which provides
direction to the welder
position of the weld, and weld quality are also described. It is
or welding operators important to use the correct welding type for the application.
for making sound and
quality production
welds as per the code
The Role SMAW Plays in Industrial
requirements Fabrication
Stick welding or SMAW is one of the oldest methods of welding.
It has been around for over a hundred years, and it is still
one of the most common processes in industrial fabrication.
Technological advances have made it even better throughout
the years for more types of manufacturing and fabrication.

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Understanding SMAW
Shielded Metal Arc Welding (SMAW) uses an electric arc to join
two metals. Because it has the ability to come in different sizes
and types, SMAW is highly adaptable to a variety of applications.
It uses alternating current or direct current, based on the electrode
required for your specific process. Larger electrodes use higher
currents, but can yield higher deposition rates.
The skill of the welder is an important factor in SMAW. KEY WORD
However, fortunately most welders get trained in SMAW in Shielded metal arc
their first stages of education, meaning that most skilled welders welding (SMAW), also
are familiar with the process. It is also one of the most trusted known as manual metal
processes in welding, because of its simplicity and versatility. arc welding (MMA or
It can be used with carbon steel, stainless steel, cast iron, and MMAW), flux shielded
arc welding or informally
more. SMAW can be also be done in any position, as well as as stick welding, is a
on different thicknesses of materials. Many times, the skill of manual arc welding
the welder determines what can actually be accomplished and process that uses a
where it can be used. consumable electrode
covered with a flux to lay
the weld.
The Benefits of SMAW
SMAW is a standard in most industries, because it has so many
benefits over other types of welding. Some of these benefits
include the following:
• It is highly portable.
• The equipment is simple and affordable.
• SMAW is not sensitive to wind.
• There’s no requirement for a separate gas shielding.
• It can be used in many different environments, in a
fabrication shop, or outdoors on a construction site, or
even on a ship.
• It has different power capabilities, gas, diesel, and
electricity, allowing it to be used in places that do not
have electrical setups.
• It can be used with many different metals.
• Welders often train in SMAW first, thus it is widely
familiar and prevalent across industries.
• Many industries are already equipped with knowledge
and technology to easily perform SMAW.

Some Disadvantages of SMAW

Although SMAW is a popular and common process, it does
have some limitations which makes it less desirable for some
projects. Some of the disadvantages of SMAW include:
• The lack of automation means that the productivity
rates are lower than other more automated processes.
• SMAW has lower deposition rates than some other
processes.

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• It relies heavily on the skill of the operator.

• It isn’t suitable for titanium or zirconium.
• It can require more cleanup due to spatter.

Does SMAW Fit Into Your Setting?

SMAW is the most common welding application for multiple reasons. Many welders have
trained in SMAW, making it easy to find qualified craftsmen, the equipment is also portable
and affordable. In addition, the equipment doesn’t have as many intricate parts as in other
types of welding, which makes it reliable and reduces the chances of mechanical breakdown.
Newer technologies are continually advancing the capabilities in the welding industry, which
increases the productivity even when it comes to stick welding.
It is important to look at all the variables of your project, from the materials to the
budget. Knowing how to pin down the most efficient process that fits the goals and design
of the project, while ensuring that all regulations of the industry are met is top priority.
Considering safety, reliability, and productivity is crucial.

Advantages
• Lower equipment cost than GTAW, FCAW and GMAW. (No bottle, gas hose, flowmeter,
and tig rig/Wire feeder needed.
• Quick Change from one material to another.
• The process lends itself to welding in confined spaces and various positions with
few problems.
• Deposition Rates faster than GTAW Manual
• Easy to move from one location to another. No Wire Feeder and Bottle.
• Some special electrodes are made for cutting/gouging
• Requires no outside shielding gas and can be used outdoors in light to medium wind.
• The ability to bend the electrode and the small space the electrode takes allows
the process to be used in comparitively tight spaces. However keep in mind that
for some jobs one of the other processes may also work or even work better. The
FCAW-Self Shielded process can weld with a very long electrode stickout.

Disadvantages
• Low deposition rate compared to GMAW/FCAW.
• Filler metal cost per weld can be greater due to a low deposition efficiency that can
vary greatly with stub length.
• Production factor is typically lower (Unless welding on various materials) due to
rod changes and chipping slag.

PROGRESS CHECK
1. Define the welder performance and welding procedure qualification.
2. Describe the fabrication process of SMAW.

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• Needs more hand eye coordination than GMAW/FCAW.

• Slag must be removed as compared to GTAW/GMAW

PROTECT COMPANY PROPERTY AND CUSTOM-

ER INTERESTS
We rely on these standards to gain the trust of customers, peers and shareholders. In keeping
with this policy the Board of Directors has adopted this Code of Business Conduct and
Ethics (the “Code”). All Company directors, officers, and employees, wherever they may be
located, are expected to read and understand this Code, to uphold these standards in day-to-
day activities, and to comply with all applicable policies and procedures. We encourage our
agents, partners, and suppliers, to read this Code in order to understand how we conduct
business.
The purpose of this Code is to set forth in writing standards that will deter wrongdoing
and that will promote:
• honest and ethical conduct, including the ethical handling of actual or apparent
conflicts of interest full, fair, accurate, timely and understandable disclosure in reports
and other documents that we file with or submit to the Securities and Exchange
Commission (“SEC”) and in other public communications that we make;
• compliance with applicable governmental laws, rules and regulations;
• protection of Company assets, without limitation, including corporate opportunities
and confidential information;
• fair dealing practices;
• the prompt internal reporting of violations of this Code; and
• assurance of accountability for adherence to this Code’s provisions.
Because the principles described in this Code are general in nature, you should also
review all applicable Company policies and procedures for more specific instruction, and
contact the Human Resources Department if you have any questions.

Your Responsibilities to the Company and its Shareholders

A. General Standards of Ethical Conduct

The Company expects all directors, officers, and employees to exercise good judgment to
ensure the safety and welfare of employees and to maintain a cooperative, efficient and
productive work environment and business organization. The Company expects all directors,
officers, and employees to act with honesty and integrity and observe the highest ethical
standards of business conduct in dealings with the Company’s customers, suppliers, partners,
service providers, competitors, employees and anyone else with whom they have contact in
the course of their job performance. These standards apply while working on our premises,
at offsite locations where our business is being conducted, at Company-sponsored business
and social events, or at any other place where you are a representative of the Company.
Directors, officers or employees who engage in misconduct (including a violation of this
Code) or whose performance is unsatisfactory may be subject to corrective action, up to
and including termination.

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Harassment
The Company seeks to provide a work environment free from harassment of any type by
ensuring that all employees are treated with mutual consideration and respect. Harassment
based on sex, race, color, religion, national origin, age, sexual preference, disability, veteran
status, and protected activity will not be tolerated.

Applicable Laws
All Company directors, officers and employees must comply with all laws, regulations, rules
and regulatory orders applicable to the Company. Company employees both foreign and
domestic must comply with laws, regulations, rules and regulatory orders of the United
States, including laws regarding insider trading, the Foreign Corrupt Practices Act and
the U.S. Export Control Act, in addition to applicable local laws. Each director, officer and
employee must acquire appropriate knowledge of the requirements relating to his or her
duties sufficient to enable him or her to recognize potential dangers and to know when to
seek advice on specific Company policies and procedures. Violations of laws, regulations,
rules and orders are also a violation of this Code and may subject the director, officer or
employee to individual criminal or civil liability, as well as to discipline action by the Company.
Employees may access the full policies related to export compliance, anti-corruption, and
insider trading on the Ethical Business Conduct portal on the intranet.

Confidentiality
Our proprietary information is valuable to both the Company and to outsiders. Only
information that has already been made available to the public (such as through press releases,
annual reports, quarterly reports, filings with the Securities and Exchange Commission,
etc.) or that must be disclosed to properly perform your job, may be provided outside the
Company. Employees should not acquire, use, access, copy, remove, modify, alter or disclose
to any third parties any confidential information for any purpose other than to fulfill job
responsibilities or in connection with Company-sponsored activities. All information and data
resident on the Company’s computers, mainframe, network, personal computers or mobile
devices are the sole and exclusive property of the Company. Care must be exercised with
respect to computer data and information to protect them against intentional or unintentional
corruption, for example, by computer viruses.
The Company’s confidential information includes trade secrets. No individual shall be held
criminally or civilly liable under any federal or state trade secret law for the disclosure of a
trade secret that is made (A) (i) in confidence to a federal, state or local government official,
either directly or indirectly, or to an attorney; and (ii) solely for the purpose of reporting or
investigating a suspected violation of law; or (B) is made in a complaint or other document
filed in a lawsuit or other proceeding, if such filing is made under seal. An individual who
files a lawsuit for retaliation by an employer for reporting a suspected violation of law may

POINTS TO REMEMBER
• If you are aware of violations of this harassment policy, you should contact your
supervisor, senior management or file a report through the Haynes Whistleblower
hotline or website. Employees may access the full Harassment policy on the Ethical
Business Conduct portal on the company intranet.

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disclose a trade secret to the attorney of the individual and use trade secret information in
the court proceeding if the individual (A) files any document containing the trade secret
under seal and (B) does not disclose the trade secret, except pursuant to court order.

Conflicts of Interest
Each of us has a duty/responsibility to the Company, our shareholders and each other. Although
this duty does not prevent us from engaging in personal transactions and investments, it
does demand that we avoid situations where a conflict of interest might occur or appear to
occur. The Company is subject to scrutiny from many different individuals and organizations.
We should always strive to avoid even the appearance of impropriety. A conflict of interest
exists where the interests or benefits of one person or entity conflict with the interests or
benefits of the Company. Whether particular conduct, relationships or transactions might be
considered to be a conflict of interest may not always be clear. Where there is any question
as to whether any conduct, relationship or transaction might be considered to be a conflict
of interest, and whether the Company might nevertheless approve such conduct, relationship
or transaction, you are strongly encouraged to contact your supervisor or the Chief Financial
Officer of the Company. Employees may access the policy related to Anti-Nepotism on the
Ethical Business Conduct portal on the intranet.

Public Disclosure
It is our policy that the information in our public communications, including SEC filings, be
full, fair, accurate, timely and understandable. All directors, officers and employees who are
involved in our disclosure process are responsible for upholding this policy. In particular,
these individuals are required to maintain familiarity with the disclosure requirements
applicable to us and are prohibited from knowingly misrepresenting, omitting, or causing
others to misrepresent or omit, material facts about us to others, whether within or outside
our company, including our external independent auditors and our internal auditors. In
addition, any director, officer or employee who has a supervisory role in our disclosure
process has an obligation to discharge his or her responsibilities diligently.
The Company’s internal operating controls and corporate reporting and disclosure
procedures are intended to prevent, deter and remedy any violation of this Code, including
but not limited to violations of applicable laws and regulations. Even the best systems of
controls and procedures, however, cannot provide absolute safeguards against such violations.
The Company and its directors, officers and employees have a responsibility to investigate
and report to appropriate governmental authorities, as required, any violations of applicable
legal and regulatory requirements relating to corporate reporting and disclosure, accounting
and auditing controls and procedures, securities compliance and other matters pertaining to
fraud against shareholders, and the actions taken by the Company to remedy such violations. 

Corporate Opportunities
Directors, officers and employees owe a duty to the Company to advance its legitimate
business interests when the opportunity to do so arises. Directors, officers and employees are
prohibited from taking for themselves (or directing to a third party) a business opportunity
that is discovered through the use of corporate property, information or position, unless we
have already been offered the opportunity and turned it down. More generally, directors,
officers and employees are prohibited from using corporate property, information or position
(including customer lists or information) for personal gain or competing with us. Sometimes
the line between personal and corporate benefits is difficult to draw, and sometimes both

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personal and corporate benefits may be derived from certain activities. The only prudent
course of conduct whenever a question arises, is to discuss the issue with your supervisor.

Fair Dealing
We have a history of succeeding through honest business competition. We do not seek
competitive advantages through illegal or unethical business practices. Each director, officer
and employee should endeavor to deal fairly with our customers, clients, service providers,
suppliers, competitors and employees. No director, officer or employee should take unfair
advantage of anyone through manipulation, concealment, abuse of privileged information,
misrepresentation of material facts, or any unfair dealing practice.

Books and Records

Federal and state laws require that all business records be prepared accurately, reliably,
and in a timely manner. The Company has established a sound system of internal controls
and considers it a priority for employees to perform responsibilities within the control
framework. It is very important that no director, officer or employee create or participate
in the creation of (or falsification or alteration of) any Company records that are intended
to mislead anyone or conceal anything improper.
Company books and records must be maintained in confidence, safeguarded from loss
and destruction, and subjected to internal control and audit procedures. Directors, officers
and employees must be honest and straightforward when dealing with internal or external
auditors with respect to the Company’s transactions, records, accounts and financial statements.

Company property

Torch
The basic oxyacetylene torch comprises:
• torch body (or handle)
• two separate gas tubes (through the handle connected to the hoses)
• separate control valves
• mixer chamber
• flame tube
• welding tip
NB  The cutting torch requires two oxygen supplies to the nozzle, one mixed with fuel
gas for preheating and a separate oxygen flow for cutting.

Hoses
Hoses between the torch and the gas regulators should be color-coded; in the UK: red for
acetylene, and blue for oxygen. Fittings on the oxygen hose have right-hand threads; while
those on the acetylene hose have left-hand threads.

Gas regulators
The primary function of a gas regulator is to control gas pressure. It reduces the high pressure
of the bottle-stored gas to the working pressure of the torch, and this will be maintained

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during welding.
The regulator has two separate gauges: a high pressure gauge for gas in the cylinder
and a low pressure gauge for pressure of gas fed to the torch. The amount of gas remaining
in the cylinder can be judged from the high pressure gauge. The regulator, which has a
pressure adjusting screw, is used to control gas flow rate to the torch by setting the outlet
gas pressure. Note Acetylene is supplied in cylinders under a pressure of about 15 bar but
welding is carried out with torch gas pressures typically up to 2 bar.

Flame traps
Flame traps (also called flashback arresters) must be fitted into both oxygen and acetylene
gas lines to prevent a flashback flame from reaching the regulators. Non-return spring-loaded
valves can be fitted in the hoses to detect/stop reverse gas flow. Thus, the valves can be
used to prevent conditions leading to flashback, but should always be used in conjunction
with flashback arresters.
A flashback is where the flame burns in the torch body, accompanied by a whistling
sound. It will occur when flame speed exceeds gas flow rate and the flame can pass back
through the mixing chamber into the hoses. Most likely causes are: incorrect gas pressures
giving too low a gas velocity, hose leaks, loose connections, or welder techniques which
disturb gas flow.

Identification of gas cylinders

Gas cylinders are color-coded. In the UK, an oxygen cylinder is black with a white/grey
shoulder; and an acetylene cylinder is maroon. Cylinders should also carry a label that gives
details of the type of gas.
Oxygen and acetylene are stored in cylinders at high pressure. Oxygen pressure can be
as high as 300 bar. Acetylene, which is dissolved in acetone contained in a porous material,
is stored at a much lower pressure, approximately 15bar.
It is vitally important to ensure that the regulator fitted to the oxygen cylinder is rated
to at least the same pressure as the cylinder. Some oxygen regulators are only rated at 215
bar and should not be used on a 300 bar cylinder. Flammable gases such as acetylene (and
propane) have left hand threads on the cylinder and regulator; the oxygen regulator and
cylinder have a conventional right hand thread. On no account should oil or grease be
allowed to come into contact with oxygen equipment.

Selection of correct nozzles

Welding torches are generally rated according to thickness of material to be welded. They
range from light duty (for sheet steel up to 2mm in thickness) to heavy duty (for steel plate
greater than 25mm in thickness). Each torch can be fitted with a range of nozzles with a
bore diameter selected according to material thickness. Gas pressures are set to give correct
flow rate for nozzle bore diameter. Proportions of oxygen and acetylene in the mixture can
be adjusted to give a neutral, oxidizing or carburizing flame. Welding is normally carried
out using a neutral flame with equal quantities of oxygen and acetylene.

Equipment safety checks

Before commencing welding it is wise to inspect the condition and operation of all equipment.
As well as normal equipment and workplace safety checks, there are specific procedures for
oxyacetylene. Operators should verify that:

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• flashback arresters are present in each gas line

• hoses are the correct color, with no sign of wear, as short as possible and not taped
together
• regulators are the correct type for the gas
• a bottle key is in each bottle (unless the bottle has an adjusting screw)
It is recommended that oxyacetylene equipment is checked at least annually - regulators
should be taken out of service after five years. Flashback arresters should be checked regularly
according to manufacturer’s instructions and, with specific designs, it may be necessary to
replace if flashback has occurred.

Health Hazard Communication

There is a statutory requirement to communicate health hazard and health risk information
to all employees. This is an extensive task and includes teaching employees about the health
effects of designated substances to which they may be exposed. Examples of such substances
include a variety of respiratory hazards which may be either byproducts of other materials’
reactions or may represent a direct exposure hazard: one might name in this connection
such materials as Sulphur dioxide; hydrogen supplied; chlorine; chlorine dioxide; carbon
monoxide; nitrogen oxides and welding fumes. Material Safety Data Sheets (MSDSs) are the
prime source of information on this subject. Unfortunately, the suppliers’ MSDSs often lack
the necessary quality of health and toxicity information and may not be available in both
official languages. This deficiency is being addressed at one of the company’s sites (and will
be extended to the other sites) through the development of one-page health information
sheets based on an extensive and well-respected database (using a commercially available
MSDS generation software system). This project was undertaken with company support by
members of the joint labor-management health and safety committee, a process which not
only solved a communication problem, but encouraged participation by all workplace parties.

Safety in Gas Welding, Cutting and Similar Processes

Oxy/fuel gas equipment has many uses - welding, cutting, heating, straightening, and descaling.
The equipment is versatile, easy to move and cheap. It is so widely used that sometimes
people forget about the dangers. Many people are injured each year by the incorrect or
careless use of oxy/fuel gas equipment. Some people die. This leaflet describes the hazards
associated with portable oxy/fuel gas equipment and the precautions for avoiding injury
and damage to property.
The main hazards are:
• fire caused by heat, sparks, molten metal or direct contact with the flame;
• explosion when cutting up or repairing tanks or drums which contain or may have
contained flammable materials;
• fire/explosion caused by gas leaks, backfires and flashbacks;
• fumes created during flame cutting;
• fire/burns resulting from misuse of oxygen;
• burns from contact with the flame or hot metal;
• crushing or impact injuries when handling and transporting cylinders

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Preventing Fire from Heat, Sparks, Molten Metal or Direct Contact with Flame
The flame from an oxy/fuel gas torch (often called a ‘blowpipe’) is a very powerful source of
ignition. Careless use of oxy/fuel torches has caused many fires. The flame will quickly set
light to combustible material such as wood, paper, cardboard, textiles, rubber, and plastics.
Many processes also generate sparks and hot spatter which can also ignite these materials.
The following precautions will help prevent fire:
• move the workpiece to a safe location for carrying out hot work;
• remove nearby combustible materials (such as flammable liquids, wood, paper,
textiles, packaging or plastics);
• Protect nearby combustible materials that cannot be moved. Use suitable guards or
covers such as metal sheeting, mineral fiber boards or fire-retardant blankets;
• Check that there are no combustible materials hidden behind walls or in partitions,
particularly if the welding or cutting will go on for some time. Some wall panels
contain flammable insulation materials, e.g. polystyrene;
• Use flame-resistant sheets or covers to prevent hot particles passing through openings
in floors and walls (doorways, windows, cable runs, etc.);
• If the consequences of a fire are severe, e.g. work inside ships, you may need to
appoint a fire watch during and after the work finishes. It is normal to maintain
fire watch for 30 minutes after hot work finishes;
• prevent flame, heat, sparks or hot spatter from landing on the hoses;
• Keep fire extinguishers nearby.

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